Electrical device and method of assembling such an electrical device

ABSTRACT

The invention relates to an electrical device ( 10 ), notably intended to control an electric machine, comprising:
         a first zone filled with an insulating material (A) and comprising a first electronic unit ( 12 ) embedded in the insulating material (A);   a second zone filled with an insulating material (B) and comprising a second electronic unit ( 18 ) embedded in the insulating material (B); and   a third zone filled with an insulating material (B) and comprising at least one electrical connection element ( 22 ) embedded in the insulating material (B), the at least one electrical connection element ( 22 ) connecting the first electronic unit ( 12 ) with the second electronic unit ( 18 );
 
in which the first and the second zone are each in contact with the third zone so that the electrical device comprises at least one space extending around the third zone and between the first and the second zone.

The subject of the invention is an electrical device intended to controlan electric machine and a method of assembling such an electricaldevice.

Usually, an electrical device intended to control an electric machine,such as a voltage converter, comprises electronic units which requireefficient insulation to dust, to liquids, to gases or else to moisture.Accordingly, insulation with the aid of a deposition of insulatingmaterial can be carried out.

However, in general, the insulation of an electrical device requires asignificant quantity of insulating material in order to guaranteeefficient insulation of the electrical device. Therefore, theseelectrical devices have high production costs.

The present invention is aimed at remedying these drawbacks by proposingan electrical device making it possible to reduce the quantity ofinsulating material required in order to insulate the electrical device,while guaranteeing efficient insulation of the said electrical device.

For this purpose, the subject of the invention is an electrical device,notably intended to control an electric machine, comprising:

-   -   a first zone filled with an insulating material and comprising a        first electronic unit, notably an electronic power unit,        embedded in the insulating material;    -   a second zone filled with an insulating material and comprising        a second electronic unit, notably an electronic control unit,        embedded in the insulating material; and    -   a third zone filled with an insulating material and comprising        at least one electrical connection element embedded in the        insulating material, the at least one electrical connection        element connecting the first electronic unit with the second        electronic unit;    -   in which the first and the second zone are each in contact with        the third zone so that the electrical device comprises at least        one space extending around the third zone and between the first        and the second zone.

In particular, the space is free of substance, notably devoid ofinsulating material.

In particular, the power electronics is intended to deliver an electriccurrent to an electric machine with the help of a voltage source.

Advantageously, in the electrical device according to the invention, thespace between the first and the second zone makes it possible todecrease the production costs of such an electrical device, by virtue ofa reduction in the quantity of insulating material required toefficiently insulate the electronic control and power units.Furthermore, this space allows circulation of air between the first andthe second zone and around the third zone, and thus better cooling ofthe electrical device by convection.

The electrical device according to the invention can also comprise oneor more of the following characteristics, considered individually oraccording to all the possible combinations:

-   -   the first, second and third zones are superposed, the first and        second zones extending substantially along parallel planes;    -   the third zone is defined at least in part by a hollow column        into which the at least one electrical connection element is        intended to be inserted, the hollow column extending between the        first and the second zone;    -   the hollow column is filled with insulating material;    -   the electrical device according to the invention also comprises        a support of an electronic unit, arranged between the first        electronic unit and the second electronic unit and comprising an        open cavity intended to receive the second electronic unit;    -   the hollow column extends from the open cavity, and is        configured to communicate with the open cavity at a first end of        the hollow column;    -   a second end of the hollow column opposite to the first end is        in contact with the insulating material in which the first        electronic unit is embedded;    -   the bottom of the open cavity comprises guidance elements for        guiding the at least one electrical connection element and        intended to guide the at least one electrical connection element        towards the second electronic unit, the guidance elements being        notably arranged at the first end of the hollow column;    -   the electrical device according to the invention also comprises        an electrical connector configured to electrically connect the        first electronic unit to at least one of the electrical elements        (phase φ, B⁺, B⁻) of an electric machine controlled by the        electrical device and/or of an electrical energy source, and        comprised at least in part in the said space extending around        the third zone and between the first and the second zone;    -   the electrical connector is arranged between the first        electronic unit and the support of the second electronic unit,        the electrical connector comprising an orifice into which the        hollow column is intended to be inserted.

The invention also pertains to a method of assembling an electricaldevice, notably intended to control an electric machine, comprising:

-   -   a step in which a first electronic unit, notably an electronic        power unit, embedded in an insulating material forming a first        zone, a second electronic unit, notably an electronic control        unit, and at least one electrical connection element an end of        which is connected to the said first electronic unit are        provided;    -   a step of connecting the at least one electrical connection        element, in which an end opposite to the end connected to the        said first electronic unit is connected to the second electronic        unit; and    -   a step of depositing an insulating material, in which the second        electronic unit is embedded in an insulating material forming a        second zone and the at least one electrical connection element        is embedded in an insulating material forming a third zone so        that the first and the second zone are each in contact with the        third zone and that the electrical device comprises at least one        space extending around the third zone and between the first and        the second zone.

Stated otherwise, a straight line passing through the first zone, thesaid space and the second zone, comprises a part included in the firstzone, a part included in the said space and a part included in thesecond zone, the said parts being contiguous.

In particular, the space is free of substance, notably devoid ofinsulating material.

In particular, the power electronics is intended to deliver an electriccurrent to an electric machine with the help of a voltage source. Forexample, the electric machine is a starter, a starter-alternator oranother electric machine onboard the vehicle.

Advantageously, the method of assembling the electrical device allowsefficient insulation of the electronic units, while guaranteeing areduction in production costs, notably by virtue of a reduction in thequantity of material required for the insulation of the electricaldevice. Furthermore, the space extending around the third zone andbetween the first and the second zone allows circulation of air betweenthe first and the second zone and around the third zone, and thus bettercooling of the electrical device by convection.

The method of assembling an electrical device according to the inventioncan also comprise one or more of the following characteristics,considered individually or according to all the possible combinations:

-   -   the method of assembling an electrical device according to the        invention furthermore comprises, before the step of connecting        the at least one electrical connection element:        -   a step in which a support of an electronic unit is provided,            the support of the electronic unit being arranged between            the first electronic unit and the second electronic unit,            and comprising an open cavity intended to receive the second            electronic unit, and a hollow column extending from the open            cavity, and communicating with the open cavity at a first            end of the hollow column;        -   a step of inserting the at least one electrical connection            element into the hollow column, in which the at least one            electrical connection element is inserted into the hollow            column with a view to its connection with the second            electronic unit, so that a second and of the hollow column            opposite to the first end is in contact with the insulating            material in which the first electronic unit is embedded;    -   the method of assembling an electrical device according to the        invention comprises a step of guiding the at least one        electrical connection element, in which the at least one        electrical connection element is guided towards the second        electronic unit with a view to its connection with the second        electronic unit by guidance elements arranged at the first end        of the hollow column;    -   the step of depositing insulating material comprises a step of        filing the hollow column, in which the hollow column is filled        with insulating material before embedding the second electronic        unit in the insulating material.

Other characteristics and advantages of the present invention willbecome apparent on reading the description and the following figures:

FIG. 1 is an exploded view according to a preferred embodiment of anelectrical device according to the invention,

FIG. 2 represents a sectional view of an electrical device according tothe preferred embodiment of FIG. 1,

FIGS. 3 and 4 represent a sectional view of the electrical device ofFIG. 1 at various steps of the method of assembling the said electricaldevice, and

FIG. 5 is a flowchart of the steps of the method of assembling theelectrical device according to a preferred embodiment of the invention.

It should be noted that these drawings have no other aim than toillustrate the text of the description and do not in any way constitutea limitation of the scope of the invention.

In the various figures, analogous elements are designated by identicalreferences.

The electrical device according to the invention is for example intendedto control an electric machine, notably an electric machine intended tobe integrated into an automotive vehicle, such as a rotating electricmachine.

The electrical device comprises at least one first electronic unit, forexample an electronic power unit, at least one second electronic unit,for example an electronic control unit, and at least one electricalconnection element intended to electrically connect the said electronicunits.

The electrical device is for example a voltage converter such asillustrated in the figures. Of course, the invention is in no waylimited to a voltage converter, but on the contrary the electricaldevice could be any other electrical device intended to control anelectric machine.

Likewise, the first electronic unit will be illustrated by an electronicpower unit, such as one or more electronic power modules and the secondelectronic unit will be illustrated by an electronic control unit, suchas an electronic control board. Of course, the electronic units could berespectively any other electronic component.

In particular, FIG. 1 represents an exploded view of a voltage converter10 comprising electronic power modules 12, in this example three innumber, a support 14 of the electronic modules, an electrical connector16, an electronic control board 18, and an electronic board support 20.

Advantageously, the voltage converter 10 is an AC/DC converter.Preferably, the voltage converter 10 is integrated into the casing ofthe electric machine.

The electronic control board 18 is notably intended to control theelectronic power modules 12. In particular, the electronic board 18 isintended to be connected electrically with the electronic power modules12 via at least one electrical connection element 22.

The electrical connector 16 is arranged between the electronic powermodules 12 and the support 20 of the electronic board. The electricalconnector 16 is configured to electrically connect the electronicmodules 12 to at least one of the electrical elements (phase φ), of theelectric machine and/or to at least one of the electrical elements (B⁺,B⁻) of an electrical energy source. The electrical elements of theelectric machine are, for example, phases φ. The electrical elements ofthe electrical energy source are for example a positive DC terminal B⁺,a negative DC terminal B⁻ or the earth. There is preferably anelectronic power module 12 per phase φ. Furthermore, as represented inFIG. 1, the electrical connector 16 comprises orifices 24 designed topermit access of the electrical connection elements 22 of the electronicmodules 12 with the electronic control board 18.

The support 14 of the electronic power unit is advantageously a boxcomprising at least one open cavity 26 having a bottom on which theelectronic power modules 12 are mounted. Advantageously, the box allowsthermal and electrical conduction, notably for earth pickup and thermaldiffusion. The open cavity 26 is intended to be filled with aninsulating material so that the electronic power modules 12 are embeddedin the insulating material. In particular, this configuration allowsefficient insulation of the electronic modules 12. Advantageously, thepower module support 14 is a heat dissipator, also called a thermaldissipator. The power modules 12 are fixed to the thermal dissipator soas to allow thermal transfer between the power modules 12 and a coolingcircuit (not represented), so as to dissipate the heat generated by theelectronic modules 12. Furthermore, the open cavity 26 for receiving theelectronic modules can comprise positioning elements (not represented)intended to position the electronic modules 12 on the support 14 in apredetermined position. These positioning elements make it possible tofacilitate and guarantee correct and fast positioning of the electronic15S modules 12 on the support 14 with a view to their electricalconnection with the electronic board 18.

The support 20 of the electronic control board is arranged between theelectronic power modules 12 and the electronic control board 18. Thesupport 20 of the electronic control board is preferably made ofinsulating substance, for example moulded from plastic.

The support 20 comprises an open cavity 28 having a bottom 30 on whichthe electronic board 18 is intended to be received.

The support 20 also comprises at least one hollow column 32 into whichthe at least one electrical connection element 22 of the electronicboard 18 with the electronic modules 12 is intended to be inserted. Thehollow column 32, notably visible in FIG. 2, extends from the opencavity 28 and is configured to communicate with the open cavity 28 at afirst end 34 of the hollow column 32. In particular, in FIG. 1, thesupport 20 of the electronic board 18 comprises three hollow columns,each hollow column being intended to receive the electrical connectionelements 22 for connecting each electronic module 12 with the electroniccontrol board 18. The open cavity 28 is intended to be filled with aninsulating material so that the electronic control board 18 is embeddedin the insulating material. The electronic control board 18 is thusinsulated in an efficient manner.

Advantageously, the electronic control board support 20 can comprise afiling element 38 for the hollow column 32. The filling element 38, alsocalled a filling channel, can have a general ramp shape, preferentiallya helical shape. An end of the filling element 38 communicates with thebottom 30 of the open cavity 28 and another end of the filling element38 communicates with a lateral wall of the hollow column 32. Preferably,a second end 36 of the hollow column 32 is in contact with theinsulating material in which the electronic module 12 is embedded. Thisconfiguration makes it possible to guarantee the filing of the hollowcolumn 32 with insulating material, and thus to ensure efficientinsulation of the electrical connection elements 22.

The electronic control board 18 can advantageously comprise an orifice48 arranged opposite the end of the channel 38 communicating with thebottom 30 of the open cavity 28. The orifice 48 of the electronic board18 allows notably the filing of the hollow column 32 with insulatingmaterial B by way of the channel 38.

Furthermore, the bottom 30 of the open cavity 28 preferably comprisespositioning elements 40 intended to position the electronic board 18 onthe support 20 in a predetermined position. Stated otherwise, thepositioning elements 40 disposed on the support 20 of the electronicboard are intended to cooperate with complementary positioning elements42 of the electronic board 18. For example, in FIG. 1, six positioningelements 40 are represented, each comprising a lug protruding from thebottom 30 of the open cavity 28, in a manner perpendicular to the bottom30. The positioning elements 40 can be of cylindrical shape asrepresented in FIG. 1. The six complementary positioning elements 42 ofthe electronic board are positioning orifices preferably exhibiting across section whose shape and dimensions are complementary to the shapeand dimensions of the positioning elements 40. For example, asillustrated in FIG. 1, the complementary positioning elements 42 exhibita circular cross section. These positioning elements 40 make it possibleto position the electronic board 18 correctly and rapidly on the support20, and thus to allow efficient electrical connection of the electronicboard 18 with the electronic power modules 12.

Moreover, the bottom 30 of the open cavity 28 advantageously comprisesguidance elements 44 for guiding the at least one electrical connectionelement 22 arranged at the first end 34 of the hollow column 32 andintended to guide the at least one electrical connection element 22towards the electronic board 18. For example, in FIG. 1, the bottom 30of the open cavity 28 comprises three groups of guidance elements 44.The guidance elements 44 comprise guidance orifices 46, advantageously aguidance orifice 46 per electrical connection element 22. The guidanceorifices 46 make it possible to recentre the electrical connectionelements 22 with a view to the electrical connection of the electronicmodule 12 with the electronic board 18 and thus to correctly connect theelectronic module 12 with the electronic board 18. Preferably, in orderto allow better recentring of the electrical connection elements 22, thecross-section of the guidance orifices 46 facing the electronic module12 is larger than the cross-section of the guidance orifices 46 facingthe electronic board 18. For example, in FIG. 2, the two guidanceelements 44 exhibit a circular cross-section and comprise afrustoconical portion followed by a cylindrical portion.

Moreover, the electrical device 10 is intended to receive insulatingmaterials A, B allowing insulation of the electronic power unit 12, ofthe electronic control unit 18 and of the electrical connection elements22. The insulating materials A, B allow insulation to dust, to liquids,to gases or else to moisture.

For example, the insulating material can be a resin, such as an epoxyresin, or an insulating gel, such as a silicone gel.

The electronic units 12, 18 of the electrical device 10 can be insulatedwith identical or different insulating materials A, B. Preferably theelectronic control and power units are insulated with an identicalinsulating material, notably with an insulating gel.

More precisely, the electrical device comprises:

-   -   a first zone filled with an insulating material A and comprising        an electronic power unit 12 embedded in the insulating material;    -   a second zone filled with an insulating material B and        comprising an electronic control unit 18 embedded in the        insulating material B; and    -   a third zone filled with an insulating material B and comprising        at least one electrical connection element 22 embedded in the        insulating material B.

The first and the second zone are each in contact with the third zone sothat the electrical device 10 comprises at least one space extendingaround the third zone and between the first and the second zone.

More precisely, as represented in FIG. 2, the open cavity 26 of thesupport 14 of the electronic power modules is filled with a layer ofinsulating material A so as to define the first zone. The open cavity 28of the support 20 of the electronic board 18 is filled with a layer ofinsulating material B so as to define the second zone. The hollow column32 is filled, notably predominantly filled, with insulating material Bso as to define the third zone. The interface between the insulatingmaterials A and B is notably situated inside the hollow column 32, inproximity to the second end 36 of the hollow column 32. Here, theinsulating materials A and B are the same insulating gels.

Stated otherwise, the insulating material A, B fills the free interiorspace of each open cavity 26, 28 around the components of the electronicboard 18 and/or of the electronic power modules 12. The insulatingmaterial A, B allows leaktightness of the electronic board 18 and of theelectronic power modules 12, notably leaktightness to dust and toliquids. The insulating material thus makes it possible to eliminate anyrisk of possible short-circuiting at the level of the electronic board18 or of the power modules 12.

Moreover, as represented in FIG. 2, the second end 36 of the hollowcolumn 32 opposite to the first end 34 is in contact with the insulatingmaterial A in which the electronic power module 12 is embedded so thatthe electrical connection elements 22 are embedded in the insulatingmaterials A, B. This configuration makes it possible to eliminate anyrisk of possible short-circuiting at the level of the interconnection ofthe electronic board 18 with the power modules 12.

Furthermore, the space lying between the electronic board 18 and thepower module 12 and surrounding the hollow column 32 is devoid ofsubstance, notably of insulating material. The space free of substance,notably of insulating material, between the first and the second zonehas, inter alia, the effect of leaving a space free for air circulation,thus allowing cooling by convection. Moreover, this configuration makesit possible to decrease the production costs of the electrical device10, by virtue notably of a saving in insulating material.

Moreover, the invention also relates to a method of assembling such anelectrical device according to the invention. Various steps of theassembling method are illustrated in FIGS. 3 to 5 and will be describedin greater detail in the subsequent description.

With regard to FIG. 5, the method of assembling the electrical devicecomprises a step S10 in which an electronic control unit 18, anelectronic power unit 12 embedded in an insulating material A forming afirst zone and at least one electrical connection element 22 an end ofwhich is connected to the said electronic power unit 12 are provided.

For example and preferably, the method of assembling the electricaldevice comprises a step S11 in which a support 14 of the electronicpower unit, here an electronic power module 12, is provided. Asrepresented in FIG. 3, the open cavity 26 of the support 14 is intendedto receive an electronic power module 12 and to be filled withinsulating material A, so that the electronic power unit 12 is embeddedin the insulating material A.

Advantageously, the method of assembling the electrical device cancomprise a step S12 in which an electrical connector 16 is provided. Thearrangement of the electrical connector 16 in relation to an electronicmodule 12 and to the electronic module support 14 is for example visiblein FIG. 4. The electrical connector 16 is comprised at least in part inthe space extending around the third zone and between the first and thesecond zone. The electrical connector 16 comprises an orifice 24designed to permit access of the electrical connection elements 22 ofthe electronic modules 12 with the electronic control board 18.

According to a preferred embodiment illustrated in FIG. 5, the method ofassembling the electrical device preferably comprises a step S13 inwhich a support 20, such as previously described, of the electroniccontrol unit 18 is provided. The support 20 of the electronic controlunit is then arranged between the electronic power unit 12 and theelectronic control unit 18. As represented in FIG. 4, the electronicboard support 20 is fixed in the electronic modules support 14 so as tobe opposite the electronic power modules 12. The support 20 preferablycomprises an open cavity 28 intended to receive the electronic controlunit 18 and a hollow column 32 such as were described previously.

Thus, the first, second and third zones are superposed, the first andsecond zones extending substantially along parallel planes.

Subsequent to step S13, the assembling method can comprise a step S14 ofinserting the at least one electrical connection element 22 into thehollow column 32. As represented in FIG. 4, the electrical connectionelements 22 are then inserted into the hollow column 32 with a view totheir connection with the electronic control unit 18. The second end 36of the hollow column 32 opposite to the first end 34 is in contact withthe insulating material A in which the electronic power unit 12 isembedded. This configuration makes it possible to eliminate any risk ofpossible short-circuiting at the level of the interconnection of theelectronic board 18 with the power modules 12, the hollow column 32being intended to be filled with insulating material B.

Advantageously, the method of assembling the electrical device cancomprise a step S15 of guiding the at least one electrical connectionelement 22. The electronic board support 20 comprises guidance elements44 for guiding the electrical connection elements 22 such as representedin FIG. 4. The electrical connection elements are guided towards theelectronic control unit 18 by the guidance elements 44 arranged at thefirst end 34 of the hollow column 32.

The method of assembling the electrical device according to theinvention furthermore comprises a step S20 of connecting the at leastone electrical connection element 22. As represented in FIG. 4, an endof the electrical connection elements 22 is connected to the electronicmodule 12 and the end opposite to the end connected to the saidelectronic power module 12 is connected to the electronic control board18.

Subsequent to step S20, the method of assembling the electrical deviceaccording to the invention comprises a step S30 of depositing aninsulating material. As illustrated in FIG. 2, the electronic module 12is embedded in a layer of insulating material A while the electronicboard 18 and the electrical connection elements 22 are embedded in alayer of insulating material B. A zone devoid of insulating material isvisible, around the electrical connection elements 22 and between thesupport 20 of the electronic control board and the insulating material Acovering the electronic power module 12. This zone devoid of insulatingmaterial allows efficient cooling of the electronic modules, whileguaranteeing insulation at the level of the electrical connectionelements 22.

Moreover, step S30 can comprise a step S31 of filling the hollow column32, in which the hollow column 32 is filled with insulating material Bbefore embedding the electronic control unit 18 in the insulatingmaterial B. The deposition of insulating material B inside the hollowcolumn 32 is performed by the filing element 38 for the electronic boardsupport 20. The filling of the hollow column 32 by the filling element38 makes it possible to fill the hollow column 32 entirely. This allowsbetter insulation of the electrical connection elements 22 and makes itpossible to avoid possible risks of short-circuiting at the level of theinterconnection of the electronic module 12 with the electronic board18.

As illustrated in FIG. 8, according to a preferred embodiment of theinvention, steps S11 to S15 can be carried out consecutively and incombination before step S20. Of course, this embodiment is not limiting,steps S11 to S15 may or may not be carried out consecutively, alone oraccording to any possible combination.

The electrical device intended to control an electric machine has beendescribed within the framework of a voltage converter intended to supplyan electric machine notably intended to supply an automotive vehicle. Ofcourse, the invention is in no way limited to the embodiment describedand illustrated, which has been given merely by way of example. On thecontrary, other applications of the electrical device in accordance withthe invention are also possible without departing from the scope of theinvention.

The invention claimed is:
 1. An electrical device for controlling anelectric machine, comprising: a first zone filled with a firstinsulating material and comprising a first electronic unit embedded inthe first insulating material; a second zone filled with a secondinsulating material and comprising a second electronic unit embedded inthe second insulating material; a third zone filled with the secondinsulating material; and an electrical connection element, wherein theelectrical connection element is embedded in its entirety by acombination of the first insulating material and the second insulatingmaterial, wherein the electrical connection element connects the firstelectronic unit with the second electronic unit, wherein the first zoneand the second zone are each in contact with the third zone so that theelectrical device comprises at least one space extending around thethird zone and between the first zone and the second zone.
 2. Theelectrical device according to claim 1, in which the first, second andthird zones are superposed, the first and second zones extendingsubstantially along parallel planes.
 3. The electrical device accordingto claim 1, in which the third zone is defined at least in part by ahollow column into which the at least one electrical connection elementis intended to be inserted, the hollow column extending between thefirst and the second zone.
 4. The electrical device according to claim3, in which the hollow column is filled with the second insulatingmaterial.
 5. The electrical device according to claim 3, also comprisinga support of an electronic unit, arranged between the first electronicunit and the second electronic unit and comprising an open cavityintended to receive the second electronic unit.
 6. The electrical deviceaccording to claim 5, in which the hollow column extends from the opencavity and is configured to communicate with the open cavity at a firstend of the hollow column.
 7. The electrical device according to claim 6,in which a second end of the hollow column opposite to the first end isin contact with the first insulating material in which the firstelectronic unit is embedded.
 8. The electrical device according to claim5, in which the bottom of the open cavity comprises guidance elementsfor guiding the at least one electrical connection element and intendedto guide the at least one electrical connection element towards thesecond electronic unit.
 9. The electrical device according to claim 5,further comprising; an electrical connector configured to electricallyconnect the first electronic unit to at least one of the electricalelements of an electric machine controlled by the electrical deviceand/or of an electrical energy source, and comprised at least in part inthe space extending around the third zone and between the first and thesecond zone.
 10. The electrical device according to claim 9, in whichthe electrical connector is arranged between the first electronic unitand the support of the second electronic unit, the electrical connectorcomprising an orifice into which the hollow column is intended to beinserted.
 11. The electrical device according to claim 1, furthercomprising: a first protective support; and a second protective support,wherein the first zone is covered by the first protective support;wherein the second zone and the third zone are covered by the secondprotective support; wherein the first protective support and the secondprotective support are distinct from each other.
 12. The electricaldevice according to claim 1, wherein: the third zone is positionedimmediately on top of the first zone, the second zone is positionedimmediately on top the third zone, the first zone, second zone, andthird zone are positioned in a vertical structure defined by a firstprotective support and a second protective support.
 13. An electricaldevice for controlling an electric machine, comprising: a first zonefilled with a first insulating material; a first circuit boardcomprising a first plurality of electronic elements, wherein the firstzone comprises the first circuit board completely surrounded by thefirst insulating material; a second zone filled with a second insulatingmaterial; a second circuit board comprising a second plurality ofelectronic elements, wherein the second zone comprises the secondcircuit board completely surrounded by the second insulating material; athird zone filled with the second insulating material; and an electricalconnection element, wherein the electrical connection element connectsthe first circuit board with the second circuit board, and wherein thefirst zone and the second zone are each in contact with the third zoneso that the electrical device comprises at least one space extendingaround the third zone and between the first zone and the second zone.